ATC Logistics specializes in forward logistics, returns, repair, and light remanufacturing of electronics. This case study details the material handling system that increased its capacity, increased accuracy, and created a more ergonomic workplace.

Barrett-Hamilton, a Little Rock-based distributor of distilled spirits, wines, and popular beers, wanted to capitalize on the burgeoning consumer demand for microbrewed beers. It needed a conveyor system up and running - and it needed it fast.

This catalog distribution center increased its output by 60% without increasing the number of order pickers or other personnel. The Container Store excels at helping its customers get organized - and that extends to organization of its own operations.

Cargill packs about 30,000 cases of beef each day at its Friona facility. Here is how a new handling system transformed that operation. Now, the company operates a new 50,000-square-foot distribution center that helps it handle increasing demand.

In the previous system, boxes of beef were stored on loaded flow racks. Paper-based order picking was inefficient and often inaccurate. In addition, workers had to handle boxes weighing as much as 110 pounds, further slowing the process.

This fully integrated system gives Fidelity unprecedented order picking speed, continuous inventory tracking, more throughput in less space, near perfect order fulfillment, and the virtual elimination of inventory-related paperwork.

"It took us an average of five minutes to handle an order with our old system. Now, we handle twenty orders in five minutes - many in as few as 12 seconds - and we're more accurate than we were before..."

The printer labeling conveyor system implemented in this retail distribution facility slashed labor costs, allowing more effective, less expensive fulfillment. "It was a pleasant surprise how quickly the productivity changed."

The Groceryworks conveyor runs at a constant 90 feet per minute, allowing pickers to pick up to 1,000 orders a day at the peak order fulfillment projected. That's using as few as 30 people to pick the entire operation.

Majors had consolidated two smaller distribution centers into its Lewisville, TX warehouse and was experiencing high order volumes because of the consolidations and a 50% increase in orders. "Our answer to increased demand has always been more people..."

Mouser Electronics is one of the largest supplier-authorized catalog distributors of electronic components in North America. This update of its Texas distribution center increased order output and shipping efficiency.

Previously, Cisco-Eagle designed an addition that more than doubled facility size from 105,000 square feet to its current 280,000 square feet. But Mouser just kept growing, averaging 33% annual increases. Updates were required to handle 4,000 daily orders

Simmons increased safety, reduced labor costs, and achieved faster throughput with its new conveyor and palletizing systems. It managed to implement the new system without interfering with its ongoing operations.

"We've had less need for contract labor and services than we have ever had. The labor cost savings for not adding positions as we grew has been significant. The accuracy is key. If we promise customers it will be there, we make it."

"We've increased quality and productivity. We have a better work environment. We improved the things like efficiency, and the quality of our work life. We simplified our process and improved every aspect of the operation."

As part of its overall e-commerce plans, Macy's Stores elected to decentralize much of its distribution and focus online distribution at smaller facilities, each located in the back of the retailers stores.